Dual yarn pile fabric



y 1961 H. F. NOWICKI 2,985,942

DUAL YARN FILE FABRIC Filed May 1, 1957 5%? WWW 6 "N'N'l'l' our INVENTOR HENRY F. NOWICKI United States Patent DUAL YARN PILE FABRIC Henry F. Nowicki, Norristown, Pa., assignor to James Lees and Sons Company, Bridgeport, Pa., a corporation of Pennsylvania Filed May 1, 1957, Ser. No. 656,743

1 Claim. (Cl. 28-78) This invention relates to pile fabric and more particularly to a rug or carpet having different pile heights in the face yarn.

The present invention is a continuation-in-part of Serial No. 624,364, filed November 26, 1956, now abandoned and has for its primary object the judicious use of separate areas of difierent pile yarns so that in one area the wear is received by relatively high pile and in a ground area yarn of a different material and preferably having more luster may be used to provide a background effect. The background yarn may be of a synthetic nature which does not have the crush resistance of the higher yarn.

It is to be clearly understood that the yarns are entirely distinct from each other and are not to be considered a blend. Such a fabric is desirably manufactured on a tufting machine in which the yarn of one characteristic is threaded through alternate needles. The yarn of the other characteristic or physical property is threaded through the remaining needles and a suitable tension device. The relative height of the loops in the two adjacent rows of stitches may be controlled so that first one yarn and then another yarn is raised or lowered as the case may be. However, unless a skip-stitch pattern is utilized, it will be understood that each row has its full complement of stitches, whether they be high or low or intermediate.

Referring now more particularly to the drawings Fig. 1 is a top view of a portion of the fabric constructed in accordance with the present invention,

Fig. 2 is a section as seen at 2-2 of Fig. 1,

Fig. 3 is a section as seen at 3-3 of Fig. 1, and

Fig. 4 is a section as seen at 44 of Fig. 1.

The invention comprises essentially the provision of high and low areas, preferably in a tufted carpet, in which the high relatively wear-resistant areas are formed of high loop pile such as wool, and the lower areas are formed of a synthetic material such as rayon. A carpet manufactured in accordance with the invention can combine the desirable features of both wool and rayon to provide a rug having long wearing and crush resistant properties as well as lower cost and high luster effects characteristic of a synthetic yarn such as rayon.

A pile fabric incorporating the invention comprises a backing 5 through which there are stitched parallel rows 2,985,942 iatented May 30, 1961 of yarn, preferably loops, shown at 6 and 7. The rows 6, 6a, and 6b are alternately tufted between rows 7,. 7a, 7b, and 70. In the preferred form of the invention; row 7 as shown in Fig. 4 is of a rayon or synthetic yarn. and contains loops 8, 8 of constant relatively low height- The yarns in rows 6, etc., however, are preferably of a natural fiber such as wool and contain areas of high loops. 9 together with areas of low loops 10in the same row. By way of example, the relatively high pile area can be all wool and the low pile area, viscose rayon. Within thescope of the invention any relatively crush resistant or long-wearing yarn or blend may be used for the high pilearea. An example of such a blend in this maximum. wear area would be 50% wool, 30% rayon, and 20% nylon. In the background area an all rayon yarn may be used or for added background effect a metallic yarns may be employed either with or without the rayon. In-v any event, the fabric produced will have a generally uniform dispersal of high pile which has long-wearing and crush resistant features. This high pile serves toprotect a low pile background area in which there may be used any yarn or blend of yarns or a moresque yarn of less long-wearing characteristics and having the ability to provide a background effect of color or luster.

As shown in Fig. 3, the high loops 9 are adjacent rows 7 of synthetic loops and extend substantially above them, whereby the background or low loop areas are not only substantially concealed, but are protected from increased wear; and the loops of the synthetic rows are supported by the natural wool yarns in such a way that permanent crushing or even temporary crushing of the low loops is avoided. Judicious selection of the areas in which the high and low loops are formed permits an extremely long-wearing carpet to be made which, at the same time, is saving in the amount of expensive yarn required, provides interesting textured or sculptured pattern effects without increased cost.

Having thus described my invention, I claim:

In a tufted textile floor covering, a ground fabric, a plurality of rows of low pile yarns comprised of synthetic fibers having a low wear resistance secured in said ground fabric, closely interspersed alternate rows of high pile yarns comprised of wool having a high Wear resistance secured in said ground fabric said rows forming an area of the floor covering having closely spaced amounts of both high and low pile, the high pile in said area overhanging adjacent lo-w pile whereby the high wear resistant high pile conceals and protects the adjacent low wear resistant low pile.

References Cited in the file of this patent UNITED STATES PATENTS 2,319,073 McElhaney May 11, 1943 2,754,578 Groat July 17, 1956 2,764,185 Mostertz Sept. 25, 1956 2,766,506 Rice Oct. 16, 1956 2,857,652 McNally et a1 Oct. 28, 1958 

